Frame structure

ABSTRACT

A frame for making outdoor kitchens or other frame structures. The frame includes an elongate rail section and an elongate joint section. The rails sections have inner bridges that are proximate to the ends of the rail sections. These inner bridges nest within outer bridges on the elongate joint sections. A central fastener may join the two bridges, more securely lining joint sections and the rail sections.

TECHNICAL FIELD

The present invention relates to devices adaptable for use in construction of outdoor kitchens.

BACKGROUND

Outdoor cooking is a popular pastime of numerous enthusiasts. Portable outdoor gas or wood grills or smokers have been used for a number of years for backyard cooking. Such devices are adequate for cooking food but they have a number of drawbacks. They usually include minimal, if any, stable surfaces needed for food preparation. Without such surfaces, the cook will either prepare items indoors or attempt to use patio tables or similar structures as ad hoc surfaces on which to prepare food. In addition, because a portable outdoor gas grill does not allow for refrigeration, items which must be kept cold are either refrigerated indoors, or kept in a cooler on ice near the grill.

One solution to this problem is to create an outdoor grill system that could include both a grill, work surfaces, storage compartment, a refrigerator if desired, and other features. A number of outdoor kitchens have been proposed. For example, U.S. Pat. App. Pub. 2004/0065313 discloses a modular outdoor kitchen comprised of a number of weather resistant modules. The modules are releasably connected together, allowing assembly and configuration. A number of the outer faces include panels to provide a weather resistant outer surface.

U.S. Pat. App. Pub. 2005/0133018 discloses a method and system for constructing a grill island or support structure. This structure includes modular units, which may be configured to hold the grill, enclose a refrigerator, store a trash bin or storage drawers, or be adapted for other purposes. Each modular unit includes a frame of interconnecting elements defining an open interior and a covering extending over the frame, generally to create a face and a top. A number of these modular units are connected together to form a unitary structure, such as a grill island.

There is presently a need for a frame system that is easy to assemble, requires only minimal tools, and is structurally strong. Such a system could be adaptable to shipping in a compact manner. The framework could serve as the frame structure for a number of different structures that require a frame.

SUMMARY

The embodiments of the presently described device include a frame structure including a plurality of rails (or a first elongate frame member) and a plurality of elongate joint sections (or second elongate frame member). Both the rails of first elongate frame member and the joint sections or second elongate frame member have associated bridge structures, with the rails or first frame member having inner bridges that nest within outer bridges on the joint sections or second frame member. At least some of the joint sections may have a tab with a central hole or other floor mounting structure. In other embodiments, the inner bridges and outer bridges may have aligning holes to allow for a fastener to join the two parts. In another embodiment, at least some of the rails may have a return flange. The joint section may also have one or more ends that join two perpendicular rail sections.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an outdoor kitchen, showing a gas grill installed in one module and a number of the modules having a front and top installed.

FIG. 2 is a perspective view of one module cube of an outdoor kitchen.

FIG. 3 is a perspective view of one module cube including a bar counter.

FIG. 4 is a perspective view of one corner module having a bar counter.

FIG. 5 is a perspective bottom view of a connector.

FIG. 6 is a side perspective view of a first embodiment of a corner brace.

FIG. 7 is a side perspective view of a second embodiment of a corner brace.

FIG. 8 is a side perspective view of a third embodiment of a corner brace.

FIG. 9 is a side perspective view of a frame module including a bar counter section.

FIG. 10 is a side perspective view of a rail section.

FIG. 10 a is a cross section of the rail of FIG. 10.

FIG. 11 is a side perspective view of a rail section.

FIG. 12 is a side perspective view of a rail section.

FIG. 13 is a side perspective view of a rail section.

FIG. 14 is a side perspective view of a joint section.

FIG. 15 is a side perspective view of a joint section.

FIG. 16A is a front perspective view of a connector part.

FIG. 16B is the connector part of FIG. 16A joining the ends of two rail sections.

FIG. 17A is a front perspective view of an alternative type of connector.

FIG. 17B is a side perspective view of the connector of FIG. 17A shown orientated for attachment to a rail section.

DETAILED DESCRIPTION

First Frame Design

With reference to FIG. 1, an L-shaped outdoor kitchen having a partial bar counter is shown. A first module cube is a section is comprised of rails 10, 12, 14, 15, 16, 18, 20, 22, 24, and 28. These rails are secured by connectors to form a cube. For example, connector 30 secures together rails 14, 18, and 24. In a similar manner, connector 32 secures rails 12, 14, and 15 and connector 34 secures together rails 16, 18, and 20. Rail 14 forms the lower front cross bar. In some instances, this cross bar can be excluded from the design to accommodate insertion of appliances like trash receptacles or refrigerators which require ground level clearance.

Once this corner cube module is assembled it may be attached to adjacent module 40. Such modules may be of a standardized height and width to allow standard size appliances to fit into the outdoor kitchen counter or island built from these modules. Module 40 is joined to an adjacent module which holds gas grill 42. This module is shown having an attached face 50 and counter top 52. This face and counter top may be selected from commercially available materials, such as granite, slate, butcher block wood, or other commercially available materials. The countertops may be attached in the conventional manner, the same way as indoor kitchen countertops.

The illustrated outdoor kitchen includes corner module 44, and bar counter modules 47, 48 including bar counter 46. All of the modules may be assembled using rails having a single cross sectional diameter. In addition, only the corner module requires braces while all the other modules require only a uniform connector. This simplicity makes the device simpler and cheaper to manufacture and assemble.

With reference to FIG. 2, a module is illustrated. This is a simple construction, and can be sold either as a kit for self assembly, as a completed module, or even as a prefab outdoor kitchen. The module consists of rails 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, and 82. These rails are made of galvanized steel or other suitable materials. These are joined together by connectors 90 a-90 h. For example, connector 90 g secures together rails 60, 80 and 82. Diagonally spaced rivet holes 94 match to holes at the end of rail 80, diagonally spaced holes 92 match to holes at the end of rail 82 and diagonally spaced holes 96 and 98 match to holes at the end of rail 60. Each of the rails has an identical cross sectional diameter and a regular pattern of holes at the end of each member section. Holes 60 a allow a connector to be secured using counter sunk rivets at one end of the rail and holes 60 b allow a connector to be secured at a second end.

Each rail is U-shaped in cross section. This cross section is the same for each rail, simplifying manufacturing and assembly. The rails have a width w and a depth d. As seen with rails 74, 78, 80, and 82, the rails are oriented such that the internal space within the module is greatest. The illustrated cube is assembled using rails of three different lengths. Four rails of each length are required.

With reference to FIG. 3, a module 100 is shown having a bar counter. The module 100 is similar to the module of FIG. 2. The bar counter is made of rails that have the same cross-sectional dimensions as the rails of FIG. 2. In addition, all of the connectors are the same connectors used in FIG. 2. One difference between the module of FIG. 2 and the module of FIG. 3 is that rear rails 118 a and 118 b are longer than the height of the front rails, instead extending to the top of the bar counter. Connector 111 attaches across the width of rail 118 a, allowing coupling to rail 115. Connector 114 a couples rail 102 a to crossbar rail 115. Similarly, on the other side connector 114 b is coupled to rail 102 b. These upright rails are then coupled to rail 120 by connectors 104 and 106, which respectively also allow attachment to rails 110 and 122. At the rear of the bar counter, rail 108 is secured by connectors 116 and 122. As in the other modules, a face may be secured to the front and sides of the module if desired, and a top secured to the top of the module, as shown in FIG. 1. In addition, the bar counter could also have a mounted a top and a bar counter face. A modified version of this module could be used for the grill.

With reference to FIG. 4, a corner module 130 with a bar counter is shown. For most modules created using the rails, only a single type of connector (the connector shown in FIG. 5) is required. For the illustrated module, three types of corner braces are used. For example, the orientation of the rails illustrated by rails 5, 7, and 9 allow the three rails to be held by the single connector 3. Rail 7 is held by the clip end of connector 3 and rails 5 and 9 are held by the clamp section of connector 3. However this is not possible unless the width of the two rails joined by the connector clamp end are oriented such that their widths extend across the connector clamp width, as is the case with rails 5 and 9. However, if the rails are in the orientation of the adjoining of rails 5, 137 and 133 at the top front corner of the module, only two rails may be joined by connector 135, namely rails 5 and 137. Corner brace 157 is used to join rails 5 and 137. As shown in FIG. 6, this corner brace includes two clamps oriented at right angles to allow securing to the ends of two rails. Corner braces 146, 165, and 167 are similar braces.

Referring again to FIG. 4, two additional types of corner braces are used. Corner brace 144 allows two perpendicular rails 134 and 132 to be joined to each other at the abutting ends of the rails. Similarly, corner brace 145 allows rails 151 and 136 to be joined to each other. These corner braces are shown in FIGS. 8 and 7, respectively.

The rest of the rails 131 a, 131 b, 137, 133, 138, 153, 132, 134, 136, 160, 169, and 151 are attached together using connectors 143, 154, 135, 161, 163, 148 150, 152, 159, 162, and 142 as illustrated. This creates a module for an outdoor kitchen as shown in FIG. 3, but one in which the bar counter top fits into a corner. Again, for the majority of the modules, only a single type of connector is required.

With respect to FIG. 5, a connector of the type used in FIGS. 1-4 is illustrated. This connector includes a clamp section 170 and a clip section 172. This clamp section 170 can be defined as having two open ends and being sufficiently long (as shown by the bracket) that it snugly fits across the width of the rail (width w in FIG. 2). The clip section 172 fits over the end of a rail, meaning that the measurement of bracketed length 175 is the width of a rail (width w in FIG. 2). The rivet holes 176, 174 and 178 are arranged on diagonals and are counter sunk. Thus, when the connector is secured to a rail using rivets, the rivets are still flush with the surface of the connector.

FIG. 6 shows a corner brace including two clamps allowing attachment of the brace across the width of two rails. The two clamps have a perpendicular arrangement. Tabs 180 and 182 are opposite each other and have diagonal rivet holes 180 a and 182 a. In a similar manner, face 186 and tab 184 have rivet holes 186 a and 184 respectively.

Two additional types of corner braces are shown in FIGS. 7 and 8. In FIG. 7, two perpendicular, outward facing sets of tabs, 194 and 196, and 190 and 192, are the attachment points for this corner brace. Counter sunk rivet holes 190 a, 192 a, 194 a, and 196 a allow attachment of the brace to rails. The corner brace 8 shown in FIG. 8 has two sets of perpendicular, inward facings tabs to allow the brace to act as a corner brace. These tabs set 200, 204 attaches to one rail and tab set 202, 206 attaches to a second rail. Counter sunk rivet holes 200 a, 202 a, 204 a, and 206 a allow the brace to be secured to the rails.

The illustrated module for making an outdoor kitchen allows simple assembly of frames which provide a durable structure for constructing outdoor kitchens. These kitchen counters may be constructed as a counter, an island, or other configuration. It may be in a L shape, a U-shape or as a line counter. The kitchen may be constructed to hold a gas grill, an under-the-counter refrigerator, a trash receptacle, drawers or cabinets for storage or other selected kitchen components. The steel or other material used for the frame is strong and durable. A variety of different counter tops and faces could be placed on the top and front of the cabinets.

The present frames could be used in a number of ways. The various modules could be assembled off site and sold as completed units. The units could be sold either with face and tops attached or without, and either as pre-fabricated modules to be joined together or as a singular, ready to use unit. Alternatively, the modules could be assembled on-site. The fact that relatively few different parts are used would allow for simple and rapid on-site assembly.

Second Frame Design

The frame design described in conjunction with FIGS. 1-8 discloses a relatively simple system to assemble. Such a system could be assembled at the installation site or could be sold as a preassembled unit. It is highly adaptable to modular configuration. In the improved frame design, the first frame design is simplified. To the extent possible, the connectors have been eliminated, and instead the frame members are joined by using an attachment structure built into the ends of the elongate frame sections. This simplifies manufacture of the system, requires shipping of fewer parts, and makes the system easier to assemble. In addition, the improved frame design may be assembled using a screwdriver and no other tools. Additional advantages of the present system will become apparent in the detailed description of the detailed embodiments.

As in the first frame design, the frame may be manufactured in a number of modules. These modules may be similar to the modules shown in FIG. 1, and can include frames of standardized height and width to allow standard size kitchen appliances or other standard sized components to fit within the interior of the space defined by the frame. Also as shown in FIG. 1, sections of the frame may include a bar counter. These modules can be added to a frame configuration in a selected location. A counter top, a face, sides, or back may be attached to the frame if desired. As in FIG. 1, any conventional counter top or face may be added to the frame once assembled. As before, the frame is strong, rigid and durable.

With reference to FIG. 9, an exemplary frame module is shown. This frame demonstrates the general principles of frame construction, which allow for design of other frame modules. The bottom of the frame is made of elongate sections 310, 312, 314, and 320. Each of these sections has a face and two sides, making the section substantially “C”-shaped in cross section. As shown in FIG. 9, section 314 has tabs 318. Tab 318 has a hole 316. These tabs allow for mounting of the unit to a floor. For example, concrete screws could be used to securely mount the illustrated module onto a concrete patio area. The sides of the frame module are elongate sections 302, 304, 306, and 308. The tops of the module elongate sections 326, 322 and 324 complete the base of this module. As in the previous figures, the orientation of the elongate section is designed to maximize the interior volume of the module. Sections 312 and 322 are oriented to allow for maximal ground clearance.

In this module a counter top is added. Side sections 308 and 306 extend to the top of the bar counter. Sections 332 and 334 are “L”-shaped, forming the sides of the bar counter. Section 338 and 336 then form the top and back of the counter respectively. Brace sections 328 and 330 give the section added rigidity.

In the illustrated frame, a door 300 is mounted to the front of the frame.

This illustrated bar top module has fewer than 20 sections (including the door). The frame sections can be disassembled and shipped flat to a user. The elongate sections can nest within each other for shipping.

FIGS. 10, 11, and 12 show elongate rail sections 400, 404 and 406 respectively. Rail section 400 is the type used as rail sections 302, 304, and 306 and 308 in FIG. 9. Rail section 4O4 is the type used as rail sections 320, 312, 338 and 336 in FIG. 9. Rail section 406 is the type used as rail sections 308 and 306 in FIG. 9. Each of these rail sections has a “C” shaped cross-section, as shown in FIG. 10 a. At lease some of these rail section also have a return flange 402, as shown in FIG. 10 a. Each rail has a front face and two sides. Rail section 406 also have end caps. At least some of the rails will have a flange extending from the edge of the side walls, as the return flange 402 in FIG. 10 a shows. This feature adds rigidity to the rail sections. An addition rail type is shown in FIG. 13, which shows rail section 408, which corresponds to sections 328 and 330 in FIG. 9. Rail section 408 is “L” shaped in cross section and acts as a brace.

FIGS. 14 and 15 show elongate joint sections 410 and 412, respectively. Joint section 410 shown in FIG. 14 has a tab 318 having a centrally located hole 316. In FIG. 14 this is shown facing up, as would be the case if this joint section were installed as one of the top sections. This same joint section could be inverted to be used on the lower lever. The two halves of this section have repeating elements when the section is divided along its length. This makes the section adaptable for use on the top or bottom and on the left or right side of a module. Thus joint section 410 corresponds to sections 310, 314, 326, and 324. In contrast, joint section 412 of FIG. 15 has an “L”-shaped face, making the joint section specific to the right or left side of the module. Thus this embodiment uses a left side and a right side joint section for sections 332 and sections 334 of FIG. 9.

A unique aspect of the present deign is a bridge on bridge method of coupling the elongate sections. Each bridge consists of an area of sheet metal that has been lanced on two sides. The bridge is punched out to the required height. In the center of the bridge a hole is punched which creates a lead hole for a fastener. The bridge is “punched out” such that the exterior surface of the rail or joint section is a level surface, and the bridge is counter sunk. This allows a screw to be inserted into the bridge's central hole and screwed in until the head of the screw is flush with the surface of the rail or is countersunk. This creates a “bridge” structure. A second, slightly smaller bridge structure on a joining part allows the two parts to be joined together. The center cut holes then can be more securely attached together with a fastener, such as a self-tapping sheet metal screw. Any appropriate alternative fastener, such as a rivet, bolt and nut, etc. may be used. One advantage of the use of screws is that the use of screws allow for assembly with tools already owned by most homeowners. Other means of attaching the elongate sections together, such as welding or gluing are possible, but are less practical and not as adaptable for on site assembly.

For example, FIG. 10 shows joint rail section having bridges 400 a, 400 b. If joint section 410 (shown in FIG. 14) were used at the top of the module frame, as shown of section 324 of FIG. 9, then bridges 400 a, 400 b would fit over bridges 410 c, 410 f. This would act to properly locate the rail section with relation to the joint. Once positioned, three screws would be used (one for each bridge pair) to secure the rail to the joint section. In a similar manner, the bridges at the other end of rail 400, bridges 400 c and 400 d could be secured to another joint of the type shown in FIG. 14. This joint would be flipped so that tab 318 rested on the floor. In this position, bridges 400 c would fit together with the bridges at 410 a of the joint section of FIG. 14. In a similar manner FIG. 12 shows rail section 406 having at its end bridges 406 a, 406 b. If rail section 406 is oriented as section 322 in FIG. 9, bridges 406 a, 406 b would fit into bridges 410 d, 410 e of joint section 410 (which would correspond to section 326 of FIG. 9).

For rail section 404 shown in FIG. 11, the end having bridges 404 a, 404 b would be clamped to a 410 joint section type in a manner similar to the joining of rail section 400 described above. Rail section 404 also has additional bridges 404 c, 404 d, which unlike the bridges already described, are not proximate to one of the ends of rail section. This allows all of bridges 410 a, 410 g of joint section 410 to be secured to rail 404. The final set of bridges on rail section 404 are bridges 404 e that are secured to a joint section of the type shown in FIG. 15 at bridges 412 c.

Rail section 408 of FIG. 13 also has a bridge 408 a to allow attachment to an rail section or joint section.

Finally, for joint section 412 of FIG. 15, bridges 412 a mate the bridges 410 b of joint section 410.

Bridges 412 e and 412 f mate with a rail at the rear of the counter. Bridges 412 b allow attachment to a rail section that acts as the top crossbar of the bar counter (like section 338 of FIG. 9).

The bridge-on-bridge fasteners have a number of advantages. First, the bridges are placed to locate the joined sections at specific locations. Once the two bridges mate, the assembler is assured that the parts are correctly positioned in relation to each other. The bridge-on-bridge connection also strengthens the structure. Each of the bridges is sunk below the front face of each section. A screw may be inserted into the hole and the head of the screw will be at or below the front face level. The fact that the bridges are countersunk allows flush surfaces (or a flush surface), which aids in the attachment of surface structures to the frame. The central hole in the bridge is adapted for use with self-tapping screws, which are quite easy to insert.

The present groups of rail sections and joint sections allows construction of basic frame cubes and linear bar tops without the need for additional connectors. For corner bar counter frames, connectors are needed. With reference to FIG. 16A, for corners the connector part 420 could join together two rail sections such as those shown in FIG. 12. In FIG. 12, rail 406 has a side bridge at one end and a corresponding bridge on the opposite side (bottom side in drawing, which is not shown). These would fit together with bridge pair 420 a, 420 c or bridge pair 420 b, 420 d. As shown in FIG. 16B, this allows right angle connector to joint together to rails, such as rails 421, and 423.

A second type of connector used for bar counters is shown in FIG. 17A. As in the first frame design, this connector has a clamp section to fit across the width of a rail section, and a clip section to clip to an end of a rail section. Bridges 430 a secure to mating bridges on the front face of a first rail. Bridges 430 b secure to mating bridges on the sides of a first rail. Bridges 430 c allow attachment to a second rail. In FIG. 17B, the connector 430 is shown aligned to join together rail sections 432 and 434.

A number of alternatives to the illustrated embodiments will be readily apparent. The present device is illustrated as used in modules for outdoor kitchens. The frames could also be adapted to other structures requiring a frame. This could include other outdoor structures, such as benches, fireplaces among other structures. In addition, the frame cold be adapted to form equipment cabinets, sheds or other structures, or any other structure in which a frame is used.

The present device may be made of steel sections, which are relatively simple to manufacture and are strong and durable. Alternative materials, including plastic, could also be used.

The disclosed frames are very easy to assemble and disassemble. This may be enhanced by the use of some indicia on the various parts as to assembly. This indicia could use colors, a letter or number, arrows, or any other indication of which sections or which parts of sections mate together. 

1. A frame structure comprising: a plurality of rails, each rail having a first and a second end; a plurality of inner bridges on said rails; a plurality of elongate joint sections; and a plurality of outer bridges on said joint sections, wherein said inner bridges are able to nest within said outer bridges when said plurality of rails are joined to said plurality of joint sections.
 2. The frame structure at claim 1, wherein at least two of the plurality of rails have a floor mounting structure.
 3. The frame structure of claim 1, wherein said plurality of rails and said plurality of joint sections include rails and joint sections for a bar top.
 4. The frame structure of claim 1, wherein said inner bridges and said outer bridges have aligning holes.
 5. The frame structure of claim 1, wherein at least two of the plurality of rails have a return flange.
 6. The frame structure of claim 1, wherein at least one of the plurality of rails is an L-shaped brace.
 7. The frame structure of claim 1, wherein said joint section has at least one end that can join to two perpendicular rails.
 8. A frame structure comprising: a plurality of first elongate frame members; at least one inner bridge proximate to each end of said first elongate frame members; a plurality of second elongate frame members; at least one outer bridge proximate to each end of said first elongate frame member, wherein said at least one inner bridge is able to nest within said at least one outer bridge, thereby joining said first and said second frame members.
 9. The frame structure of claim 8, further including a plurality of fasteners extending through each pair of inner and outer bridges.
 10. The frame structure of claim 9, wherein said fastener is a screw.
 11. The frame structure of claim 8, wherein at least two of the first elongate frame members include a tab positioned to allow floor mounting of the frame member.
 12. The frame structure of claim 8, wherein at least two of the second elongate frame members include a return flange running a majority of a length of the at last two of the second elongate frame members. 